just a quick update of this weekend's progress. The timing belt tensioner I had ordered did not fit. I think it is for a TDI. I got a couple of parts from autohaus AZ that did not fit and I think that is the issue. It says AAZ on the engine code, but it also says TDI so I think it is a mix of parts. I went to Autozone, Pepboys, and Napa and no one had a VW timing belt tensioner. Anyway since the tensioner looks just like my 1.6D tensioner I just ordered one of those and priority shipped it. Fingers crossed it will get here midweek. My silicone and aluminum bits for the intake are due to get here thursday. With no further issues next weekend should be the one.
on with the photos.
Here is the headgasket in place on the studs.
and here with the head torqued down to 80ft.lbs. That is the ARP specification, but I have read some people have taken them higher. What is the consensus on this?
One issue I did discover with the fitting of the PD150 intake is with the turbo oil supply line. However it was pretty easy to bend it a bit with a tubing bender and get it to work. The other issue I foresee is that my fitting for my boost gauge hose is very close to the turbine housing and is actually touching the heat shield between. I am going to try and find a kevlar jacket for a sparkplug wire to insulate it and route it as far above as possible.
here you can see the tighter bend in the oil line.
I have almost everything bolted back up. I just need to get the timing done so that I can finish it up.
One issue I am having is that the alternator bracket for this car is unusual. The bentley calls it out as with powersteering and without AC. It has a spring mounted under it and it acts as the tensioner for the serp belt. All the replacements I have been able to find look like the one on the right. It seems to me I have one of two options and neither is great.
1. move the guts from the working alternator with the wrong housing into the bad alternators housing
2. find the bracket and tensioner that will hold the working alternator. I'm not even sure about this because I think it was positioned above the AC compressor which I will not be running, and do not have
Plan C of course is to rig something up.
Someone has had to have encountered this before. What do you suggest I do to sort this out?